Integrated power block

Abstract

A digital power conversion system is described with a control system, power system, DC bus system, and AC bus system housed in a case. The user-programmable control system outputs pulse-width modulated (PWM) signals and input/output (I/O) signals. The power system uses these PWM signals to drive integrated power transistors to achieve a variety of power conversion functions. The DC bus system includes positive and negative DC buses accessible via positive and negative DC terminals and is connected to the power system, while the AC bus system comprises AC buses accessible via AC terminals and is also connected to the power system. The system provides an efficient and integrated power electronics platform at its rated ranges by harnessing digital power conversion and other techniques.

What is claimed is: 
     
         1 . A system for digital power conversion ( 1000 ), comprising:
 a case ( 1100 ) comprising an insulating outer shell and an insulating internal material;   a control system ( 1200 ) housed in the case,
 wherein the control system is configured by a software framework to output pulse-width modulated (PWM) signals and input/output (I/O) signals; 
   a power system ( 1300 ) housed in the case,
 wherein the power system is configured to receive and operate in accordance with the PWM signals; 
   a DC bus system ( 1400 ) housed in the case and electrically coupled to the power system,
 wherein the DC bus system comprises one or more DC buses, each individually comprising a positive DC bus and a negative DC bus, and 
 wherein the positive DC bus and the negative DC bus of each of the one or more DC buses are each externally accessible via a corresponding pair of DC terminals comprising a positive DC terminal and a negative DC terminal; and 
   an AC bus system ( 1500 ) housed in the case and electrically coupled to the power system, wherein the AC bus system comprises one or more AC buses, and
 wherein each of the one or more AC buses is externally accessible via an AC terminal; 
   
     
     
         2 . The system for digital power conversion of  claim 1 , wherein the case further comprises a conductive internal lining disposed between the insulating outer shell and the insulating internal material, configured to act as a Faraday cage. 
     
     
         3 . The system for digital power conversion of  claim 1 , wherein the control system comprises a digital signal processing subsystem ( 1210 ) comprising one or more digital signal processing circuits, wherein the digital signal processing subsystem is configured to generate and transmit the PWM signals and the I/O signals, the I/O signals comprise serial/communication I/O signals, and wherein the control system further comprises an externally accessible high density connector ( 1220 ) electrically coupled to at least one of the I/O signals. 
     
     
         4 . The system for digital power conversion of  claim 1 , wherein the control system further comprises a communication interface subsystem ( 1230 ) and one or more externally accessible user interface connectors ( 1240 ), the communication interface subsystem comprises a signal isolator ( 1231 ), and wherein the communication interface subsystem electrically couples the serial/communication I/O signals to the one or more externally accessible user interface connectors. 
     
     
         5 . The system for digital power conversion of  claim 1 , wherein the power system comprises:
 a logic power subsystem ( 1310 ) comprising one or more logic power circuits, electrically coupled to the DC bus system;   a power failsafe subsystem ( 1320 ), electrically coupled to the logic power subsystem and comprising sensing elements;   a gate driver subsystem ( 1330 ) comprising one or more gate driver circuits, each gate driver circuit being electrically coupled to the power failsafe subsystem and to the PWM signals; and   a switching device subsystem ( 1340 ) comprising one or more semiconductor transistor circuits, each semiconductor transistor circuit being electrically coupled to the gate driver subsystem, and the switching device subsystem being electrically coupled to the DC bus system or the AC bus system.   
     
     
         6 . The system for digital power conversion of  claim 5 , wherein the power system further comprises an insulated metal substrate layer ( 1350 ) bonded to the power system, and
 wherein the insulated metal substrate layer is externally accessible and is thermally coupled to at least one of the one or more semiconductor transistors.